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Patent 2608994 Summary

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(12) Patent Application: (11) CA 2608994
(54) English Title: PROTECTIVE PADDING AND PROTECTIVE PADDING SYSTEMS
(54) French Title: REMBOURRAGE PROTECTEUR ET SYSTEMES DE REMBOURRAGE PROTECTEUR
Status: Dead
Bibliographic Data
(51) International Patent Classification (IPC):
  • A41D 13/015 (2006.01)
  • A41D 13/05 (2006.01)
  • A42B 3/12 (2006.01)
  • A63B 71/08 (2006.01)
  • A63B 71/10 (2006.01)
(72) Inventors :
  • DORIA, MASON T. (United States of America)
  • HUBER, CHRISTOPHER A. (United States of America)
(73) Owners :
  • REVISION MILITARY S.A.R.L. (Luxembourg)
(71) Applicants :
  • MINE SAFETY APPLIANCES COMPANY (United States of America)
(74) Agent: NORTON ROSE FULBRIGHT CANADA LLP/S.E.N.C.R.L., S.R.L.
(74) Associate agent:
(45) Issued:
(86) PCT Filing Date: 2006-03-24
(87) Open to Public Inspection: 2007-04-12
Examination requested: 2011-03-08
Availability of licence: N/A
(25) Language of filing: English

Patent Cooperation Treaty (PCT): Yes
(86) PCT Filing Number: PCT/US2006/010844
(87) International Publication Number: WO2007/040604
(85) National Entry: 2007-11-16

(30) Application Priority Data:
Application No. Country/Territory Date
11/133,090 United States of America 2005-05-19

Abstracts

English Abstract




The present invention provides pads and padding systems for use in protective
helmets, and particularly ballistic helmets. Generally, the pad includes a
first, outer layer which provides substantial impact resistance and a second,
inner layer which provides cushioning and comfort. The pad does not require
the use of a moisture-proof, non-perforated, encapsulating layer since both
layers provide little resistance to fluid flow. The pad may also include a
cover made of moisture-wicking material.


French Abstract

L'invention concerne des éléments de rembourrage et des systèmes de rembourrage à utiliser dans des casques de protection, et notamment des casques de protection balistique. D'une manière générale, l'élément de rembourrage comprend une première couche externe conférant une résistance aux chocs importante et une seconde couche interne conférant un rembourrage et un certain confort. L'élément de rembourrage ne nécessite pas de couche d'encapsulation résistant à l'humidité et non perforée, du fait que les deux couches confèrent un peu de résistance à un écoulement de fluide. L'élément de rembourrage peut comprendre également un élément couvrant conçu dans un matériau d'inhibition de l'humidité par capillarité.

Claims

Note: Claims are shown in the official language in which they were submitted.





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What Is Claimed Is:


1. A pad for use in cushioning contact with a body comprising:

at least one section of an outer layer of a flexible, resilient, energy
absorbing material, the
outer layer being adapted to pass fluids therethrough;

at least one section of an inner layer adjacent the section of the outer layer
and positioned
inside the section of the outer layer when worn on the body, the inner layer
being of a flexible,
resilient material and being less stiff than the outer layer, the inner layer
being adapted to pass
fluids therethrough; and

wherein the pad permits fluids to pass therethrough in a direction generally
perpendicular to
the body and, after saturation of the pad by immersion in water, subsequent
removal of bulk
water from the pad by shaking and drying, the pad exhibits a weight gain that
is less than
30%.


2. The pad of claim 1 wherein the pad exhibits a weight gain that is less than

20%.


3. The pad of claim 1 wherein the pad exhibits a weight gain that is less than

10%.


4. The pad of claim 3 wherein the outer layer comprises a plurality of
discrete
beads of substantially elastic, resilient material positioned adjacent one
another and having
interstitial spaces therebetween through which air and water can pass.


5. The pad of claim 3 wherein the inner layer comprises a first layer, a
second
layer spaced from the first layer and a plurality of yarns connecting the two
layers.


6. The pad of claim 4 wherein the inner layer comprises a first layer, a
second
layer spaced from the first layer and a plurality of yarns connecting the two
layers.


7. The pad of claim 6 wherein the beads of the outer layer are adhered
together
and are waterproof.





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8. The pad of claim 7 wherein the inner layer is formed from one or more
hydrophilic materials.


9. The pad of claim 6 wherein the inner layer and the outer layer are
encompassed
by a cover.


10. The pad of claim 9 wherein the cover comprises an inner cover material
placed
adjacent to and over an inner surface of the inner layer, the inner cover
comprising a
hydrophilic, wicking material.


11. The pad of claim 10 wherein an outer surface of the outer cover material
includes a fastening mechanism to fasten the pad to an article worn on the
body.


12. The pad of claim 11 wherein the fastening mechanism comprises hooks or
loops for use in a hook-and-loop type connection.


13. A pad for use in cushioning contact with a body comprising:

at least one section of an outer layer of a flexible, resilient, energy
absorbing material, the
outer layer comprising a plurality of discrete beads of substantially elastic,
resilient material
positioned adjacent one another and having interstitial spaces therebetween
through which
fluids can pass; and

at least one section of an inner layer adjacent the section of the outer layer
and positioned
inside the section of the outer layer when worn on the body, the inner layer
being of a flexible,
resilient material and being less stiff than the outer layer, the inner layer
being adapted to pass
fluids therethrough.


14. The pad of claim 13 wherein the inner layer comprises a first layer, a
second
layer spaced from the first layer and a plurality of yarns connecting the two
layers.


15. A protective helmet comprising a shell and a plurality of pads therein
adapted
to be placed in cushioning contact with a body, each pad being adapted to pass
fluids
therethrough in a direction generally perpendicular to the body and
comprising:




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an outer layer of a flexible, resilient, energy absorbing material adjacent to
the
shell, the outer layer being adapted to pass fluids therethrough; and

an inner layer adjacent the outer layer and positioned on the opposite side of

the outer layer from the shell, the inner layer being of a flexible, resilient
material and being
less stiff than the outer layer, the inner layer being adapted to pass fluids
therethrough; and
wherein after saturation of one of the plurality of pads by immersion in
water, subsequent
removal of bulk water from the pad by shaking and drying, the pad exhibits a
weight gain that
is less than 30%.


16. The helmet of claim 15 wherein each pad exhibits a weight gain that is
less
than 20%.


17. The helmet of claim 15 wherein each pad exhibits a weight gain that is
less
than 10%.


18. A protective helmet comprising a shell and an impact cap therein for use
in
cushioning a body, the impact cap comprising a layer of a flexible, resilient,
energy absorbing
first material that can pass fluids therethrough, and at least one section
adjacent the first
material comprising a flexible, resilient second material that is adapted to
pass fluids
therethrough and is less stiff than the layer of first material.


19. The protective helmet of claim 18 further comprising a plurality of
sections of
the second material adjacent the first material.


20. The protective helmet of claim 18 wherein the energy absorbing first
material
comprises a plurality of substantially elastic, resilient material positioned
adjacent one another
and having interstitial spaces therebetween through which air and water can
pass.


Description

Note: Descriptions are shown in the official language in which they were submitted.



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Title
PROTECTIVE PADDING AND PROTECTIVE PADDING SYSTEMS

Background of the Invention

[0001] The present invention relates generally to protective padding or
cushions and to
protective padding or cushioning systems, and, particularly, to protective
padding aiid padding
systems for use in protective helmets.

[0002] Although several embodiments of the present invention are discussed in
connection with the use thereof as protective pads and/or padding systems in
protective
helmets, one skilled in the art appreciates that the protective padding and
protective padding
systems of the present invention have wide applicability for uses other than
in connection with
protective helmets.

[0003] In a number of protective helmets, a webbing system has been used to
suspend
a helmet shell on the wearer's head. In the case of military helmets, the
space between the
webbing and the helmet shell (fabricated, for example, from KEVLAR materials
available
from DuPont) contributes to the impact performance of the helmet.
Additionally, such
airspace also facilitates cooling within the helmet.

[0004] Webbing suspension systems, however, can result in undesirable pressure
points, leading to discomfort. Recently, webbing suspension systems in certain
helmets,
including certain military helmets, have been replaced by padding systems. For
example, in
the MICH or ACH combat helmets available from Mine Safety Appliances Company
of
Pittsburgh, Pennsylvania, a plurality of comfort pads of different shapes and
sizes can be
positioned within the helmet in a configuration determined by the user in
accordance with the
manufacturer's recommendation. A hook-and-loop type fastening system is, for
exainple,
used to removably attach the pads to the interior of the helmet shell. The
removable pads
provide for a customized fit, improving weight distribution and promoting
comfort and
balance. The pads also dissipate energy for protection of the user from head
trauma.
Moreover, the pads provide an airspace between the helmet shell and the user
to promote
cooling.


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[0005] Such a padding or cushioning system is disclosed in U.S. Patent No.
6,467,099.
That padding or cushioning structure includes a plurality of pads, each having
a body-facing
side, a spaced load-facing side, and a layered assembly intermediate between
the two sides.
The layered assembly includes (a) an acceleration-rate-sensitive, cushioning
core structure
and (b) a fully-jacketing, moisture-proof, non-perforated but gas-permeable
barrier layer
completely encapsulating the core structure to block completely any flow of
moisture from the
outside of the pad into the core structure. When under the influence of an
elevated, localized,
non-atmospheric pressure applied to and on the pad's body-facing side, the
acceleration-rate
sensitive, cushioning core flows in a manner which tends to dissipate or
distribute such
pressure. The layered assembly can also include (for example, at least on the
body-facing side
of the pad, and on the outside of said barrier layer) a moisture-wicking layer
operable to wick
away moisture presented to the pad on its body-facing side.

[0006] In general, pads or cushions for use in protective helmets are
preferably
lightweight so as to reduce the overall weight of the helmet. The pads should
also provide
comfort and impact resistance over a wide range of environmental conditions
(including, for
example, wide ranges of temperature, atmospheric pressure, and moisture).
Moreover, such
pads should also provide for adequate air movement and heat transfer.
Currently available
padding systems meet such conditions with varying degrees of success.

[0007] It thus remains desirable to develop improved protective padding and
protective padding systems.

Summary of the Invention

[0008] Generally, the present invention provides a protective padding or
cushioning
system for use in cushioning contact with a body (for example, in a protective
helmet
comprising a plurality of pads of the present invention). Each pad comprises
at least one
section of an outer layer of a flexible, resilient, energy absorbing material
that is adapted to
pass fluids theretlirough, and at least one section of an inner layer,
adjacent the section of the
outer layer, and positioned inside the section of the outer layer when worn on
the body. The
inner layer is of a flexible, resilient material that is less stiff than the
outer layer. The inner


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layer is also adapted to pass fluids therethrough. The pad permits fluids to
pass therethrough
in a direction generally perpendicular to the body, and afler saturation of
the pad by
immersion in water, subsequent removal of bulk water from the pad by shaking
the pad by
hand for one minute in various orientations, and drying of the pad for one
hour at 77 F and
50% relative humidity, the pad has a weight gain that is less than 30%.
Preferably, the weight
gain of the pad is less than 20%. More preferably, the weight gain of the pad
is less than 10%.

[0009] In one embodiment, the outer layer comprises a plurality of discrete
beads of
substantially elastic, resilient material, positioned adjacent one another and
having interstitial
spaces therebetween througli which air and water can pass. Preferably the
beads are
waterproof. In one embodiment, the inner layer comprises a first layer and a
second layer
spaced from the first layer and a plurality of yams connecting with the two
layers. The inner
layer can, for example, be formed from one or more hydrophilic materials.

[0010] The pad of the present invention can further include a cover comprising
an
imier cover material placed adjacent to and over an inner surface of the inner
layer and an
outer cover material connected to the inner cover material to encompass the
inner layer and
the outer layer. The inner cover can, for example, comprise a hydrophilic,
wicking material
that can be treated for increased comfort. The outer cover material can be
permanently
connected to the iiuier cover material along the perimeter of the pad.

[0011] The pad may also include a fastening mechanism to fasten the pad to an
article
worn on the body, such as a helmet. In one embodiment, the fastening mechanism
comprises
hooks or loops for use in a hook-and-loop type connection.

[0012] The present invention also provides a protective helmet including a
shell and a
plurality of pads as described above within the shell adapted to be placed in
cushioning
contact with the head of the user.

[0013] In a further aspect, the present invention provides a protective helmet
including
a shell and an impact cap therein for use in cushioning a body. The impact cap
includes a
layer of a flexible, resilient, energy absorbing first material that can pass
fluids therethrough.
The first material can include a plurality of discrete beads of substantially
elastic, resilient


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material positioned adjacent one another and having interstitial spaces
therebetween through
which fluids can pass. The impact cap can also include at least one section
adjacent the first
material comprising a flexible, resilient second material that is adapted to
pass fluids
therethrough and being less stiff than the layer of first material.

[0014] As illustrated by the above-described helmet including an impact cap,
cushioning pads or systems of the present invention can be formed in many
alternative
configurations. Impact caps (for use, for example, in a firefighter's or other
protective helmet)
and other cushioning systems, can be made from the material used as the outer
layer of the
pads of the present invention as described above. In the impact caps and other
cushioning
pads or systems (for example, cushioning pads or systems specifically shaped
or formed to
cover parts of the body other than the head) of the present invention,
individual comfort
sections made, for example, from the material used as the inner layer of the
pads of the
present invention as described above can be placed on the inside of the impact
cap or other
cushioning pad or system. These comfort sections can be permanently attached
to the impact
cap or other cushioning system with adhesive or removably attached with the
hook-and-loop
type fasteners. As used herein, the term "pad" refers generally to both flat
and formed or
shaped cushioning devices or systems.

[0015] In still a further aspect, the present invention provides a pad for use
in
cushioning contact with a body including at least one section of an outer
layer of a flexible,
resilient, energy absorbing material. The outer layer includes a plurality of
discrete beads of
substantially elastic, resilient material positioned adjacent one another and
having interstitial
spaces therebetween through which fluids can pass. The pad further includes at
least one
section of an inner layer adjacent the section of the outer layer and
positioned inside the
section of the outer layer when worn on the body. The inner layer is of a
flexible, resilient
material and is less stiff than the outer layer. The inner layer is also
adapted to pass fluids
therethrough. The inner layer can, for example, include a first layer, a
second layer spaced
from the first layer and a plurality of yams connecting the two layers.


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Brief Description of the Drawings

[0016] Other aspects of the invention and advantages thereof will be discerned
from the
following detailed description when read in connection with the accompanying
drawings, in
which:

[0017] Figure lA illustrates a top plan view of one embodiment of a pad of the
present
invention.

[0018] Figure 1B illustrates a cross-section view of the pad of Figure lA.

[0019] Figure 2A illustrates an underside view of an embodiment of a
protective
helmet of the present invention (without chin strapping) including several
pads of the present
invention.

[0020] Figure 2B illustrates a prospective view of the helmet of Figure 2A as
worn by
a user (without chin strapping).

[0021] Figure 3A illustrates a top plan view of a multi-pad padding system of
the
present invention.

[0022] Figure 3B illustrates a cross-sectional view of a portion of the
padding system
of Figure 3A.

[0023] Figure 4A illustrates an embodiment of a bottom view of an impact cap
of the
present invention.

[0024] Figure 4B illustrates a side view of the impact cap of Figure 4A
positioned
within a protective helmet (shown in dashed lines).

Detailed Description of the Invention

[0025] Figures lA and 1B illustrate an embodiment of a pad or cushion 10 of
the
present invention for use, for example, as a body pad or cushion. Pad 10 is
particularly suited
for use in ballistic-resistant helmet systems although it can be used in any
protective helmet.


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In the embodiment of Figures 1 A and 113, pad 10 includes a first, outer or
helmet-side layer of
materia120 (see Figure 1B) which provides substantial impact resistance.
Preferably, the
outer layer materia120 is lightweight and consistently absorbs impact energy
(that is, provides
"impact resistance") even when cycled over multiple impacts. Also, the impact
resistance of
the material of outer layer 20 preferably remains in a desirable range over a
wide range of
ambient or environmental conditions. For example, in one embodiment, the
impact resistance
is acceptable over a temperature range of approximately 15 F to 130 F.
Similarly, neither
rapid changes in atmospheric pressure (i.e., air transport) nor the presence
of water (either in
the form of high humidity or the presence or liquid water) substantially
affects the impact
resistance and/or the breathability of the material of outer layer 20.

[0026] As used herein, the designation "inner" refers generally to a
component,
surface or direction toward the body when an article is worn, and the
designation "outer"
refers generally to a component, surface or direction away from the body when
an article is '
worn.

[0027] In one embodiment, the material of outer layer 20 includes fluid flow
pathways
that provide little resistance to fluid flow (gas and/or liquid) or has a
porosity such that the
material does not retain water tlierein. This low resistance to fluid flow
also facilitates air
movement or breathability. Preferably, the material of outer layer 20 allows
fluid flow such
that when a 3" x 3" x 5/8" sample of the material is saturated with water by
being submerged
in 3 feet of water for 12 hours, shaken by hand in various orientations for
one minute to
remove bulk water, and allowed to dry for one hour in a standard ambient
environment of
77 F and 50% relative humidity on a screen rack or other device, the water
retained in the
sample results in a weight gain of less than 30%, preferably less than 20%,
more preferably
less than 15% and even more preferably less than 10%. In the studies of the
present
invention, the materials were placed on a screen rack or other similar device,
such that water
flowed via gravity generally in a direction perpendicular to orientation of
the body when
pad 10 is in use - see arrow F in Figure 1B and arrow F' in the expanded
portion of
Figure 1B.


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[0028] The material of outer layer 20 is also preferably lightweight. In that
regard, the
density of the material of outer layer 20 is preferably less than 6 lb/ft3,
more preferably less
than 41b/ft3, and even more preferably less than 3 lb/ft3.

[0029] The material of outer layer 20 can, for example, be formed from a
plurality of
resilient beads that are assembled into a pad section or layer (for example,
by use of an
adhesive material). Such a material is commercially available from Brock USA
of Boulder,
Colorado and is described generally in U.S. Patent No. 6,301,722, the
disclosure of which is
incorporated herein by reference. In general, such materials are porous,
closed-cell
composites, formed by adhering together resilient, waterproof, closed cell
polyiner beads
(typically, only at their tangent points). The resultant material is a
durable, non-absorptive
composite. The material allows fluids such as air and water to flow freely
through interstitial
spaces in the material in all directions. Examples of the closed-cell
polymeric materials
incorporated into such materials include polypropylene or polyethylene foam,
blends of
polypropylene and polyethylene foams, and rubberized polypropylene and/or
polyethylene
foams. Impact resistant materials formed from a plurality of resilient
polymeric beads are
described generally in U.S. Patent Nos. 6,301,722, 6,032,300, 6,098,209,
6,055,676 and
5,920,915, the disclosures of which are incorporated herein by reference.

[0030] Such materials are considered time-rate dependent, energy dissipating
materials that absorb energy in several ways. Under low impact energy, the
individual beads
propagate to fill interstitial air voids in the material, thereby dissipating
energy through
interstitial friction. Under higher energy impacts, the beads themselves can
further deform,
effecting mechanical energy dissipation. Under even higher energy impacts, the
adhesive
bonds joining the beads can fracture, thereby dissipating further energy. In
the
saturation/drying test described above, such materials exhibited a weight gain
of
approximately 8% or less. The density of such materials (when dry) was
approximately 2.1 lb/ft3.

[0031] Pad 10 further includes a second, inner or body-side layer 30 which
provides
cushioning and comfort. Although, outer layer 20 as described above provides
very good
impact resistance over a wide range of conditions, such materials can be
somewhat


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uncomfortable when placed against the body. Like outer layer 20, inner layer
30 preferably
provides for passage of fluids such as water and air therethrough. However,
inner layer 30
can be less rigid or stiff than outer layer 20, thereby providing increased
comfort to a user.

[0032] Preferably, the material of inner layer 30 has sufficiently low
resistance to fluid
flow therethrough such that when a 3" x 3" x 1/4" sample of the material is
saturated with
water by being submerged in 3 feet of water for 12 hours, shaken by hand in
various
orientations for one minute to remove bulk water and allowed to dry for one
hour in a
standard ambient environment of 77 F and 50% relative humidity on a screen
rack or other
device, the water retained in the sample results in a weight gain of less than
30%. Indeed,
materials having the preferred physical characteristics of the material for
inner layer 30 can
exhibit weight gains of less than 10%, less than 3% and even less than 1%.

[0033] Like the material for outer layer 20, the material of inner layer 30 is
also
preferably liglitweight. In that regard, the density of the material of inner
layer 30 is
preferably less than 6 lb/ft3, more preferably less than 41b/ft3, and even
more preferably less
than 3 lb/ft3. Indeed, given the desired physical characteristics of the
material for inner
layer 30, materials having a density of less than 1 lb/ft3 can be used.

[0034] Inner layer 30 in a number of embodiments of the present invention is a
resilient, collapsible material that defines spaces therethrough to provided
low resistance to
fluid flow. In several embodiments of the present invention the material of
inner layer 30 was
a three-dimensional knit spacer fabric as described, for exaniple, in U.S.
Patent
Nos. 6,627,562 and 6,103,641, the disclosures of which are incorporated herein
by reference.
Such materials are commercially available from Gehring Textiles, Inc. of New
York, New
York. In general, such materials include a first fabric layer 32 made from
high performance,
high tenacity yarns and a second fabric layer 34 of an open mesh construction
to facilitate air
circulation. The material also includes a plurality of high performance yarns
36 (typically,
monofilament yarns) connecting the two layers. The connecting, high
performance yarns 36
provide a buckling colunm effect to provide resilient compressibility. The
materials of inner
layer 30 can be hydrophilic to enhance transport of body fluids away from the
body, keeping
the skin dry (for example, by capillary action). In general, inner layer 30
provides some


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impact resistance or energy absorbance or dissipation function, but typically
less than that
provided by outer layer 20. One or more of the materials of inner layer 30 can
be treated
chemically to enhance performance including its water wicking ability. The
materials can be
woven in the warp, weft and Z dimension.

[0035] In the saturation/drying test described above, such materials exhibited
a weight
gain of less than 1%. Preferably, inner layer 30 is less dense and thus adds
less weight per
unit thickness to pad 10 than does outer layer 20. The three-dimensional laiit
spacer fabrics
described above are typically very light in weight with densities less than 1
lb/ft3 and do not
add appreciable weight to pad 10. Combining the results of the
saturations/drying studies of
the materials of outer layer 20 and inner layer 30, pads 10 exhibited a weight
gain of less than
8% in such studies.

[0036] The pads of the present invention, including outer layer 20 and inner
layer 30,
without any cover layer thereon (which can be an absorbent wicking material as
described
below), preferably exhibit a weight gain of less than 30% after saturation of
the pad by
immersion in water, subsequent removal of bulk water from the pad by shaking
the pad for
one minute, and drying of the pad for one hour at 77 F and 50% relative
humidity. Preferably,
the weight gain of the pad is less than 20%. More preferably, the weight gain
of the pad is
less than 10%. Each of outer pad layer 20 and inner pad layer 30 can be tested
individually as
described above and the results combined to provide a measurement for the
assembled pad.
Alternatively, inner layer 20 and outer layer 30 can be tested together. In
several
embodiments of the present invention, outer layer 20 and inner layer 30 were
adjacent, but not
connected, in assembled pad 10. Individual testing of inner layer 20 and outer
layer 30 was
thus performed. Outer layer 20 and iimer layer 30 can be connected (for
example, via an
adhesive) in assembled pad 10, but care should be taken to not interfere with
fluid flow
through the pad in a significant manner. Outer layer 20 can, for example, be
adhered to inner
layer 30 using relatively small spots of adhesive that are spaced from each
other to prevent
significant interference with fluid flow through pad 10.

[0037] Pad 10 can further include an inner cover layer 40, which comes into
contact
with the body of the user. The material for cover layer 40 is preferably a
hydrophilic, wicking


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material that absorbs moisture resulting, for example, from perspiration and
transfers it away
from the body (for example, from the head when used in a helmet) through, for
example,
capillary action. In one embodiment, cover layer 40 was fabricated from nylon,
polyester,
and/or other hydrophilic material which was conditioned by brushing or napping
one side to
thereby comfortably contact the user's body. Other embodiments can, for
example, include
other fabric conditioning to enhance wicking or comfort characteristics such
as resistance to
heat, flame, bacteria or fungus. Hydrophilic cover layer 40 wicks perspiration
toward and
even into adjoining inner layer 30 or outer layer 20. Airflow tlirough outer
layer 20 and inner
layer 30 causes evaporation of moisture held within the capillaries of cover
layer 40 or passed
into inner layer 30 or outer layer 20 and thereby promotes cooling.

[0038] Preferably pad 10 also includes an outer, cover layer 50 which can, for
example, be connected or sealed to inner cover layer 40 about a perimeter 60
of pad 10,
thereby fully encompassing or, enclosing outer layer 20 and inner layer 30
within a cover
formed by inner cover layer 40 and outer cover layer 50. In the embodiment of
Figures lA
and 1 B, pad 10 includes a relatively thin layer of polyurethane film 70 (for
exaniple 5 mil.)
used to seal inner cover layer 40 to outer cover layer 50 by, for example,
heat sealing or
ultrasonic welding. However, imier cover layer 40 and outer cover layer 50 can
be connected
in many alternative manners as long as the connection is suitable to withstand
common usage
of pad 10. For example, inner cover layer 40 and outer cover layer 50 can be
connected by
sewing.

[0039] In the embodiment of Figures lA and 1B, the outer surface of outer
cover
layer 50 includes a connector material such as a loop material 52 as commonly
used in hook-
and-loop type fasteners. Preferably, all the materials used in the various
layers of pad 10
provide relatively low resistance to fluid flow as described above. By
providing for the
relatively free flow of fluids (gas and/or liquid) through the pad of the
present invention,
enclosing, moisture-proof barrier layers used in connection with some known
padding systems
are unnecessary and undesirable for use in the present invention.

[0040] Figures 2A and 2B illustrate an embodiment of a military helmet 100
including
a shell 110 of ballistic-resistant material such as KEVLAR. Pads l0a lOb and 1
Oc


CA 02608994 2007-11-16
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-11-
(constructed generally as described above for pad 10) are illustrated in
Figure 2A connected to
the interior of helmet shell 110. In that regard, helmet shell 110 includes
hook-type fastening
areas 120 at various positions thereon to which the loop materials 52a, 52b
and 52c (not
shown in Figure 2A, but essentially the same as loop materia152 of pad 10) on
the outer cover
surfaces of pads 10a, 10b and 10c, respectively, are removably connectible.
Pads of various
sizes and shapes can be connected to helmet shell 110 in a manner controlled
by the user to
improve the comfort and fit of helmet 100, but within the guidelines specified
by the helmet
manufacturer. While Figures 2A and 2B show a military helmet 100, various
other protective
helmets including fire helmets and hard hats can be used in the present
invention.

[0041] In several embodiments of the present invention, the total pad
thickness
(approximately, the thickness of outer layer 20 added to the thickness of
inner layer 30) was in
the range of approximately 0.75 to 1.0 inches. The thickness of inner cover
layer 30 was
approximately 0.25 inches. Preferably, inner layer 30 contacted outer layer 20
without an
intervening layer of material and without any adhesive or other bonding
connection
therebetween. In this embodiment, the pad, when assembled as a system of
components, was
designed to compress no more than 0.25 inches in any area (that is, the
thickness of inner
layer 30). It was found that this thickness of inner layer 30 was sufficient
to account for
differences in head shape and to provide stability. If a pad becomes
uncomfortable as a result
of conlplete compression of inner layer 30 and, thereby, contact with outer
layer 20 for a
particular user, the overall thickness of the pad may be incorrect for that
user and can be
adjusted accordingly.

[0042] In general, a 25% compression test on the pad system can be used to
determine
if a material is suitable for use as inner layer 30. For such a compression
test, a force gage is
used to conlpress a 0.50" diameter round attachment the required distance
(that is, 25% or 1/4
of the thickness of the tested material). The force required in pounds is then
divided by the
area of the 0.5" diameter round attachment to calculate a pressure in units of
pounds per
square inch or psi. In the studies of the present invention, samples of inner
layer 30 that were
0.25 inches thick were tested in combination with samples of outer lay 20 at
room teinperature
(approximately 25 C). Preferably, the pressure determined in the 25%
compression test is not
greater than 1.2 psi. More preferably, the pressure is in the range of
approximately 0.6 to


CA 02608994 2007-11-16
WO 2007/040604 PCT/US2006/010844
-12-
1.0 psi. In this range, the material will provide comfort while maintaining
stability.
Preferably, the 25% coinpression pressure remains within a suitable range over
a wide
variation in environmental conditions (for example, temperature, pressure and
moisture
conditions as described above).

[0043] As illustrated in Figures 2A and 2B, a plurality of pads of the present
invention
can be formed in generally any configuration within common cover layers. In
the
embodiment of Figures 3A and 3B, four pad sections 210a, 210b, 210c and 210d
are enclosed
within a common inner cover layer 240 and a common outer cover layer 250 to
form a
padding system 200. In general, the layers of padding system 200 are the same
in
composition as the layers of pad 10 and like components are numbered similarly
to
corresponding components of pad 10 with the addition of 200 thereto. For
example,
Figure 3A illustrates a cross-sectional view of a central portion of padding
system 200
encompassing generally trapezoidal shaped padding sections 210b and 210c.
Padding
section 210c includes an outer layer 220c and an imier layer 230c
corresponding to outer
layer 20 and inner layer 30 of pad 10. Inner cover layer 240 extends over the
entirety of pad
system 200 and is connected to outer cover layer 250 using heat sealing or
sonic welding of an
intermediate polyurethane layer 270 in regions 260 around and between padding
sections 210a, 210b, 210c and 210d. A loop surface 252 is provided on the
outer surface of
outer cover layer 250 for connection to a hook fastener as described above.

[0044] The material of outer layer 20 as described above is readily formable
(for
example, molded or thermomolded) into a wide variety of shapes. The other
layers of the
pads of the present invention are readily conformable to any such shape. In
one embodiment
of the present invention, such layers can be formed into an impact cap 310
(see Figures 4A
and 4B) as described, for example, in U.S. Patent Nos. 4,286,339, 5,044,016
and 6,032,297,
the disclosures of which are incorporated herein by reference.

[0045] Impact cap 310 of Figures 4A and 4B is formed to have an outer section
or
layer 320 which has the physical characteristics of outer layer 20 of pad 10
described above.
In one embodiment, outer section 320 is formed from a material comprising a
plurality of
resilient beads (as described above for outer layer 20 of pad 10) that are
formed to the shape


CA 02608994 2007-11-16
WO 2007/040604 PCT/US2006/010844
-13-
of impact cap 310. As described above, such materials are commercially
available from
Brock USA of Boulder, Colorado and are described, for example, in U.S. Patent
No. 6,301,722. A border or protective perimeter 324 (for example, formed from
a polymeric
material) can be placed or formed around the bottom perimeter of impact cap
310 to prevent
damage or fraying.

[0046] An inner layer or individual comfort pads or sections made, for
exaniple, from
a material suitable for use as imier layer 30 of pad 10 is preferably provided
between the head
of the user and outer layer or section 320. In the embodiment illustrated in
Figure 4A,
individual sections of such a material (two pads or sections 330a and 330b are
illustrated) are
removably attached to outer section 320 using fasteners 316 such as hook-and-
loop type
fasteners. As is clear to one skilled in the art, other types of fastening
systems can be used for
removable or nonremovable connection of inner sections 330a, 330b etc. to
outer section 320.
Moreover, in an alternative embodiment, an inner section can be formed to be
generally
coextensive with the inner wall of outer layer 320.

[0047] Figure 4B illustrates a helmet 400 including impact cap 310 placed
within
helmet she11410. In the embodiment of Figure 4B, impact cap 310 is removably
held within
helmet shell via a plurality of hook-and-loop type fastening systems 416. As
is clear to one
skilled in the art, many types of fastening systems can be used to removably
or nonremovably
attach impact cap 310 within helmet she11410.

[0048] In general, the pads and padding systems of the present invention are
easily
fabricated at relatively low cost. Moreover, the pads of the present invention
provide
increased heat dissipation, increased perspiration evaporation, lower water
retention and less
sensitivity to environmental conditions than currently available pads used in
connection with
protective helmets and particularly ballistic-resistant helmets. The materials
of the pads of the
present invention provide multi-impact resistance (for example, as determined
during cyclic
durability type compression) at very low weight. Moreover, the pads of the
present invention
are readily fabricated from materials that are inert and resistant to repeated
washings and
exposure to a wide range of field conditions.


CA 02608994 2007-11-16
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-14-
[0049] Although the present invention has been described in detail in
comiection with
the above embodiments and/or exainples, it should be understood that such
detail is
illustrative and not restrictive, and that those skilled in the art can make
variations without
departing from the invention. The scope of the invention is indicated by the
following claims
rather than by the foregoing description. All changes and variations that come
within the
meaning and range of equivalency of the claims are to be embraced within their
scope.

Representative Drawing
A single figure which represents the drawing illustrating the invention.
Administrative Status

For a clearer understanding of the status of the application/patent presented on this page, the site Disclaimer , as well as the definitions for Patent , Administrative Status , Maintenance Fee  and Payment History  should be consulted.

Administrative Status

Title Date
Forecasted Issue Date Unavailable
(86) PCT Filing Date 2006-03-24
(87) PCT Publication Date 2007-04-12
(85) National Entry 2007-11-16
Examination Requested 2011-03-08
Dead Application 2014-11-25

Abandonment History

Abandonment Date Reason Reinstatement Date
2013-11-25 R30(2) - Failure to Respond
2014-03-24 FAILURE TO PAY APPLICATION MAINTENANCE FEE

Payment History

Fee Type Anniversary Year Due Date Amount Paid Paid Date
Registration of a document - section 124 $100.00 2007-11-16
Application Fee $400.00 2007-11-16
Maintenance Fee - Application - New Act 2 2008-03-25 $100.00 2007-11-16
Maintenance Fee - Application - New Act 3 2009-03-24 $100.00 2009-02-23
Maintenance Fee - Application - New Act 4 2010-03-24 $100.00 2010-01-25
Request for Examination $800.00 2011-03-08
Maintenance Fee - Application - New Act 5 2011-03-24 $200.00 2011-03-18
Maintenance Fee - Application - New Act 6 2012-03-26 $200.00 2012-02-14
Maintenance Fee - Application - New Act 7 2013-03-25 $200.00 2013-03-04
Registration of a document - section 124 $100.00 2013-03-06
Registration of a document - section 124 $100.00 2013-03-06
Owners on Record

Note: Records showing the ownership history in alphabetical order.

Current Owners on Record
REVISION MILITARY S.A.R.L.
Past Owners on Record
DORIA, MASON T.
HUBER, CHRISTOPHER A.
MINE SAFETY APPLIANCES COMPANY
REVISION BALLISTICS LTD.
Past Owners that do not appear in the "Owners on Record" listing will appear in other documentation within the application.
Documents

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Document
Description 
Date
(yyyy-mm-dd) 
Number of pages   Size of Image (KB) 
Abstract 2007-11-16 1 63
Claims 2007-11-16 3 119
Description 2007-11-16 14 726
Drawings 2007-11-16 3 66
Representative Drawing 2008-02-12 1 11
Cover Page 2008-02-12 1 43
Drawings 2007-11-17 3 101
Description 2013-02-21 14 695
Claims 2013-02-21 3 117
Assignment 2007-11-16 9 516
Prosecution-Amendment 2007-11-16 2 108
Prosecution-Amendment 2011-03-08 2 89
Prosecution-Amendment 2012-08-22 4 176
Prosecution-Amendment 2013-02-21 18 917
Assignment 2013-03-06 15 413
Prosecution-Amendment 2013-05-24 3 137